Bottoms upgrading and low coke fluid catalytic cracking catalyst

ABSTRACT

A microspherical fluid catalytic cracking (FCC) catalyst includes Y zeolite and a gamma-alumina.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 62/507,451, filed on May 17, 2017, the contents of which are incorporated herein by reference in their entirety.

FIELD

The present technology is generally related to petroleum refining catalysts. More specifically, the technology is related to microspherical fluid catalytic cracking (FCC) catalysts including a gamma alumina containing matrix, and methods of preparing and using such catalysts.

BACKGROUND

Catalytic cracking is a petroleum refining process that is applied commercially on a very large scale. Catalytic cracking, and particularly fluid catalytic cracking (FCC), is routinely used to convert heavy hydrocarbon feedstocks to lighter products, such as gasoline and distillate range fractions. In FCC processes, a hydrocarbon feedstock is injected into the riser section of a FCC unit, where the feedstock is cracked into lighter, more valuable products upon contacting hot catalyst circulated to the riser-reactor from a catalyst regenerator.

Excessive coke and hydrogen are undesirable in commercial catalytic cracking processes. Even small increases in the yields of these products relative to the yield of gasoline can cause significant practical problems. For example, increases in the amount of coke produced can cause undesirable increases in the heat that is generated by burning off the coke during the highly exothermic regeneration of the catalyst. Conversely, insufficient coke production can also distort the heat balance of the cracking process. In addition, in commercial refineries, expensive compressors are used to handle high volume gases, such as hydrogen. Increases in the volume of hydrogen produced, therefore, can add substantially to the capital expense of the refinery.

Since the 1960s, most commercial fluid catalytic cracking catalysts have contained zeolites as an active component. Such catalysts have taken the form of small particles, called microspheres, containing both an active zeolite component and a non-zeolite component in the form of a high alumina, silica-alumina (aluminosilicate) matrix. The active zeolitic component is incorporated into the microspheres of the catalyst by one of general techniques known in the art, such as those in U.S. Pat. No. 4,482,530, or U.S. Pat. No. 4,493,902.

Fluid cracking catalysts which contain silica-alumina or alumina matrices are termed catalysts with “active matrix.” Catalysts of this type can be compared with those containing untreated clay or a large quantity of silica, which are termed “inactive matrix” catalysts.

It is believed that the alumina serves to provide sites for cracking gasoil and resid feeds. While moderate amounts of Lewis acidity are desired, it is believed that the silicon in the Al₂O₃ creates an undesired, strong Lewis and Bronsted sites that tend to produce coke. Coke, while needed in order to operate FCC units, is usually produced in larger than optimal amounts in FCC catalysis. Thus, reductions in coke selectivity are desirable. The present inventors discovered that FCC catalysts that include a matrix material that contains gamma alumina, either doped or un-doped with rare earth elements, advantageously resulted in a catalyst that had high bottoms upgrading and low coke yield.

SUMMARY

In one aspect, a microspherical fluid catalytic cracking (FCC) catalyst including Y zeolite and a gamma-alumina is provided. In some embodiments, the gamma-alumina includes a rare earth element or an alkaline earth element. In some embodiments, the catalyst includes Y-zeolite. In some embodiments, the catalyst further includes χ-alumina, θ-alumina, δ-alumina, κ-alumina, boehmite, or mixtures of two or more thereof. In further embodiments, the catalyst includes amorphous material or kaolin that has been subjected to calcination through an exotherm.

In one aspect, a method of making a zeolitic fluid catalytic cracking catalyst is provided, the method including:

-   -   pre-forming precursor microspheres that include a non-zeolitic         material and gamma-alumina, and     -   in situ crystallizing a zeolite on the pre-formed microspheres         to provide the zeolitic microsphere material.

In some embodiments, Y-zeolite is crystallized on the precursor microspheres.

In one aspect, a method of cracking a hydrocarbon feed is provided, that includes contacting said feed with a FCC catalyst including a microspherical fluid catalytic cracking (FCC) catalyst comprising Y zeolite and gamma-alumina. In some embodiments, the method results in a gasoline yield of greater than 1% gasoline at constant coke, when compared to contacting the feed with a FCC catalyst that does not comprise gamma-alumina. In some embodiments, the method results in 1% lower bottoms at constant coke, when compared to contacting the feed with a FCC catalyst that does not comprise gamma-alumina. In some embodiments, the method results in 10% lower coke at constant bottoms cracking, when compared to contacting the feed with a FCC catalyst that does not comprise gamma-alumina.

In one aspect, a microspherical catalyst including gamma-alumina is provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 provides the results from ACE testing of lanthanum doped Al₂O₃ containing FCC catalyst samples.

FIGS. 2A-2B provide the results from CRU testing of two different lanthanum doped Al₂O₃ containing FCC catalyst samples.

FIGS. 3A-3B provide the results from CRU testing of lanthanum doped gamma-Al₂O₃ and χ-Al₂O₃ mixture and crystalline boehmite containing FCC catalyst samples.

DETAILED DESCRIPTION

Various embodiments are described hereinafter. It should be noted that the specific embodiments are not intended as an exhaustive description or as a limitation to the broader aspects discussed herein. One aspect described in conjunction with a particular embodiment is not necessarily limited to that embodiment and can be practiced with any other embodiment(s).

As used herein, “about” will be understood by persons of ordinary skill in the art and will vary to some extent depending upon the context in which it is used. If there are uses of the term which are not clear to persons of ordinary skill in the art, given the context in which it is used, “about” will mean up to plus or minus 10% of the particular term.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the elements (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the embodiments and does not pose a limitation on the scope of the claims unless otherwise stated. No language in the specification should be construed as indicating any non-claimed element as essential.

As used herein, the term “catalyst” or “catalyst composition” or “catalyst material” refers to a material that promotes a reaction.

As used herein, the term “fluid catalytic cracking” or “FCC” refers to a conversion process in petroleum refineries wherein high-boiling, high-molecular weight hydrocarbon fractions of petroleum crude oils are converted to more valuable gasoline, olefinic gases, and other products.

“Cracking conditions” or “FCC conditions” refers to typical FCC process conditions. Typical FCC processes are conducted at reaction temperatures of 450° to 650° C. with catalyst regeneration temperatures of 600° to 850° C. Hot regenerated catalyst is added to a hydrocarbon feed at the base of a rise reactor. The fluidization of the solid catalyst particles may be promoted with a lift gas. The catalyst vaporizes and superheats the feed to the desired cracking temperature. During the upward passage of the catalyst and feed, the feed is cracked, and coke deposits on the catalyst. The coked catalyst and the cracked products exit the riser and enter a solid-gas separation system. e.g., a series of cyclones, at the top of the reactor vessel. The cracked products are fractionated into a series of products, including gas, gasoline, light gas oil, and heavy cycle gas oil. Some heavier hydrocarbons may be recycled to the reactor.

As used herein, the term “feed” or “feedstock” refers to that portion of crude oil that has a high boiling point and a high molecular weight. In FCC processes, a hydrocarbon feedstock is injected into the riser section of a FCC unit, where the feedstock is cracked into lighter, more valuable products upon contacting hot catalyst circulated to the riser-reactor from a catalyst regenerator.

As used herein, the term “resid” refers to that portion of crude oil that has a high boiling point and a high molecular weight and typically contains contaminant metals including Ni, V, Fe, Na, Ca, and others. The contaminant metals, particularly Ni and V, have detrimental effects on catalyst activity and performance. In some embodiments, in a resid feed operation one of Ni and V metals accumulate on the catalyst, and the FCC catalyst composition is effective to contact nickel and vanadium during cracking.

As used herein, the term “non-zeolitic component” refers to the components of a FCC catalyst that are not zeolites or molecular sieves. As used herein, the non-zeolitic component can comprise binder and filler.

As used herein, the term “zeolite” refers to is a crystalline aluminosilicate with a framework based on an extensive three-dimensional network of oxygen ions and have a substantially uniform pore distribution.

As used herein, the term “intergrown zeolite” refers to a zeolite that is formed by an in situ crystallization process.

As used herein, the term “in sin crystallized” refers to the process in which a zeolite is grown or intergrown directly on/in a microsphere and is intimately associated with the matrix or non-zeolitic material, for example, as described in U.S. Pat. Nos. 4,493,902 and 6,656,347. The zeolite is intergrown within the macropores of the microsphere, such that the zeolite is uniformly dispersed on the matrix or non-zeolitic material. The zeolite is intergrown directly on/in the macropores of the precursor microsphere such that the zeolite is intimately associated and uniformly dispersed on the matrix or non-zeolitic material.

As used herein, the term “incorporated catalyst” refers to a process in which the zeolitic component is crystallized and then incorporated into microspheres in a separate step.

As used herein, the terms “preformed microspheres” or “precursor microspheres” refer to microspheres obtained by spray drying and calcining a non-zeolitic matrix component and a gamma-alumina.

As used herein, the term “zeolite-containing microsphere” refers to a microsphere obtained either by in situ crystallizing a zeolite material on pre-formed precursor microspheres or by microspheres in which the zeolitic component is crystallized separately and then mixed with the precursor microspheres.

In one aspect, a microspherical fluid catalytic cracking (FCC) catalyst includes a Y zeolite and a gamma-alumina. In some embodiments, the catalyst includes about 1 wt % to about 60 wt % of the gamma-alumina. In some embodiments, the catalyst includes about 10 wt % to about 40 wt % of the gamma-alumina. In particular embodiments, the catalyst includes about 30 wt % the gamma-alumina.

In some embodiment described herein, the catalyst may further include χ-alumina, δ-alumina, θ-alumina, κ-alumina, boehmite, or mixtures of two or more thereof. In particular embodiments, the catalyst may include a mixture of gamma-alumina and one or more of χ-alumina, δ-alumina, θ-alumina, κ-alumina, and boehmite. In some embodiments, the catalyst may include a mixture of gamma-alumina, χ-alumina, and one or more of δ-alumina, θ-alumina, κ-alumina, and boehmite.

In one aspect, the gamma-alumina may further include a rare earth element, an alkaline earth element, or a mixture of any two or more such elements. For example, the gamma-alumina may include a rare earth elements. In particular embodiments, the rare earth element may be ytterbium, gadolinium, cerium, lanthanum, or a mixture of any two or more thereof. In particular embodiments, the rare earth element is lanthanum. In some embodiments, the gamma-alumina includes alkaline earth metals. In further embodiments, the alkaline earth metal is at least one of barium, calcium, or magnesium, or a mixture of any two or more thereof. In particular embodiments, the alkaline earth metal is barium. In some embodiments, the rare earth or alkaline earth elements are present in an amount of about 0.1 wt % to about 12 wt %. In some embodiments, the rare earth or alkaline earth elements are present in an amount of about 1 wt % to about 10 wt %. In a particular embodiment, the gamma-alumina includes about 1% to about 5% lanthanum. In a particular embodiment, the gamma-alumina includes about 1% to about 3% lanthanum. In particular embodiments, the gamma-alumina includes about 1% to about 5% barium. In a particular embodiment, the gamma-alumina includes about 1% to about 3% barium.

In some embodiments, the gamma-alumina, χ-alumina, δ-alumina, θ-alumina, κ-alumina, or boehmite may further include a rare earth element, an alkaline earth element, or a mixture of any two or more such elements as described herein in any embodiment. For example, the gamma-alumina, χ-alumina, δ-alumina, θ-alumina, κ-alumina, or boehmite in the catalyst may include a rare earth element, including but not limited to, ytterbium, gadolinium, cerium, lanthanum, or a mixture of any two or more thereof. In particular embodiments, the rare earth element may include lanthanum. In some embodiments, the gamma-alumina, χ-alumina. δ-alumina, θ-alumina, κ-alumina, or boehmite in the catalyst may include an alkaline earth element. In some embodiments, the alkaline earth element may include barium, calcium, magnesium, or a mixture of any two or more thereof. In particular embodiments, the alkaline earth metal includes barium. In particular embodiments, the rare earth elements or alkaline earth elements are present in an amount of about 0.1 wt % to about 12 wt %, about 1 wt % to about 10 wt %, about 1% to about 5 wt %, or about 1 wt % to about 3%.

The FCC catalyst may have a phase composition including at least 10 wt % zeolite. In some embodiments, the FCC catalyst has a phase composition including at least 60 wt % zeolite. The FCC catalyst of the present technology may have a phase composition that includes at least about 30 wt % Y-zeolite. In some embodiments, the catalyst has a phase composition that includes at least about 40 wt % Y-zeolite. In particular embodiments, the catalyst has a phase composition that includes at least about 60 wt % Y-zeolite. In particular embodiments, the catalyst has a phase composition that includes at least about 65 wt % Y-zeolite.

The FCC catalyst of the present technology may further include mullite. In some embodiments, the FCC catalyst may include about 5% to about 40 wt % mullite. In some embodiments, the phase composition further includes at least about 20 wt % mullite.

The FCC catalyst may have a phase composition including zeolite, mullite, and amorphous material. The FCC catalyst may have a phase composition including Y-zeolite, mullite, and amorphous material. In some embodiments, the phase composition further may include at least about 30 wt % amorphous material.

The Y-zeolite may be crystallized as a layer on the surface of a matrix, wherein the matrix comprises gamma-alumina. In some embodiments, the matrix also includes kaolin that has been subjected to calcination through an exotherm. In further embodiments, the matrix includes about 20 wt % to about 60 wt % kaolin that has been subjected to calcination through an exotherm. In particular embodiments, the matrix includes about 30 wt % kaolin that has been subjected to calcination through an exotherm.

In some embodiments, the Y-zeolite of the FCC catalyst may be ion-exchanged to reduce the sodium content of said catalyst to less than 0.5% by weight Na₂O. In particular embodiments, the Y-zeolite may be ion-exchanged to reduce the sodium content of said catalyst to less than 0.3% by weight Na₂O.

In some embodiments, the Y-zeolite may further include a rare earth element in the range of 0.1% to 12% by weight. In some embodiments, the rare earth element may be lanthanum, cerium, praseodymium, neodymium, or a mixture of any two or more. In particular embodiments, the rare earth element may be lanthanum. In further particular embodiments, the Y-zeolite may be ion-exchanged to include the rare earth element. In some embodiments, the FCC catalyst includes a lanthanum-exchanged zeolite crystallized in-situ in a porous kaolin matrix.

The FCC catalyst may have a matrix that comprises about 30% gamma-alumina, about 30% of kaolin that has been subjected to calcination through its characteristic exotherm, about 40% metakaolin. In some embodiments, the gamma-alumina may be doped with a rare earth element such as lanthanum. In some embodiments, FCC catalyst includes at least about 20% Y-zeolite crystallized in or on the matrix. In some embodiments, the FCC catalyst is ion-exchanged to reduce the sodium content of said catalyst is less than 0.3% by weight Na₂O. In some embodiments, the Y-zeolite further includes a rare-earth element such as lanthanum in the range of about 0.1% to about 5% by weight.

In some embodiments, the Y-zeolite has a unit cell parameter of less than or equal to 24.75 Å. In some embodiments, the Y-zeolite has a unit cell parameter of less than or equal to 24.60 Å. In some embodiments, the Y-zeolite has a unit cell parameter of less than or equal to 24.55 Å. In some embodiments, the Y-zeolite has a unit cell parameter of from about 24.10 Å to about 24.70 Å.

The FCC catalyst average particle size may be from about 60 to about 100 micrometers. In some embodiments, the FCC catalyst has an average particle size of about 60 to about 90 micrometers. In some embodiments, the FCC catalyst has an average particle size of about 60 to about 80 micrometers.

In one aspect, a microspherical catalyst comprising gamma-alumina is provided. In one embodiment, the microspherical catalyst includes about 1 wt % to about 80 wt % of the gamma-alumina. In some embodiments, the microspherical catalyst includes about 10 wt % to about 60 wt % or about 10 wt % to about 40 wt % of the gamma-alumina. In particular embodiments, the microspherical catalyst includes about 10 wt % to 70 wt % of the gamma-alumina.

The gamma-alumina in the microspherical catalyst may include a rare earth element. For example, this may include ytterbium, gadolinium, cerium, lanthanum, or a mixture of any two or more thereof. In particular embodiments, the rare earth element may include lanthanum. In some embodiments, the gamma-alumina in the microspherical catalyst may include an alkaline earth element. In some embodiments, the alkaline earth element may include barium, calcium, magnesium, or a mixture of any two or more thereof. In particular embodiments, the alkaline earth metal includes barium. In some embodiments, the gamma-alumina in the microspherical catalyst includes the rare earth element or the alkaline earth element in an amount of about 0.1 wt % to about 12 wt %. In a particular embodiment, the gamma-alumina includes about 1% to about 5% lanthanum. In a particular embodiment, the gamma-alumina includes about 1% to about 3% lanthanum. In particular embodiments, the gamma-alumina includes about 1% to about 5% barium. In a particular embodiment, the gamma-alumina includes about 1% to about 3% barium.

The microspherical catalyst may further include kaolin that has been subjected to calcination through an exotherm. In some embodiments, the microspherical catalyst includes about 20 wt % to about 60 wt % kaolin that has been subjected to calcination through an exotherm. In particular embodiments, the microspherical catalyst includes about 40 wt % kaolin that has been subjected to calcination through an exotherm.

The microspherical catalyst may include at least about 10 wt % Y-zeolite. In particular embodiments, the Y-zeolite is crystallized as a layer on the surface of the microspherical catalyst.

In one aspect, methods of making the FCC catalysts described herein. In general, the active zeolitic component may be incorporated into the microspheres of the catalyst by one of two general techniques. In one technique, the zeolitic component is crystallized and then incorporated into microspheres in a separate step. In the second technique, the in-situ technique, microspheres are first formed and the zeolitic component is then crystallized in the microspheres themselves to provide microspheres containing both zeolitic and non-zeolitic components.

In one aspect, a method of making a zeolitic fluid catalytic cracking catalyst is provided, the method including:

-   -   pre-forming precursor microspheres including a non-zeolitic         material and gamma-alumina; and     -   in situ crystallizing a zeolite on the pre-formed microspheres         to provide the zeolitic microsphere material.

In some embodiments, the in situ crystallizing includes

-   -   mixing the precursor microspheres with sodium silicate, sodium         hydroxide, and water to obtain an alkaline slurry; and     -   heating the alkaline slurry to a temperature, and for a time,         sufficient to crystallize at least about 10 wt % NaY-zeolite in         the microspheres.

In some embodiments, the alkaline slurry is heated for a time sufficient to crystallize at least about 30% by weight, Y-zeolite in or on the pre-formed microspheres.

In some embodiments, the precursor microspheres may further include χ-alumina, δ-alumina, θ-alumina, κ-alumina, boehmite or mixtures of two or more thereof. In particular embodiments, the precursor microspheres may include a mixture gamma-alumina and one or more of χ-alumina, δ-alumina, θ-alumina, κ-alumina, and boehmite. In some embodiments, the precursor microspheres may include a mixture of gamma-alumina, χ-alumina, and one or more of δ-alumina, θ-alumina, κ-alumina, and boehmite.

In some embodiments, the zeolitic microspheric material may be isolated or separated from the crystallization liquor after contacting. The isolation may be carried out by commonly used methods such as filtration. In further embodiments, the zeolitic microspheric material may be washed or contacted with water or other suitable liquid to remove residual crystallization liquor.

The method may further include mixing the zeolitic microspheric material with an ammonium solution prior to or subsequent to contacting with the crystallization liquor, wherein the zeolitic microspheric material includes Y-zeolite in the sodium form prior to the mixing with the ammonium solution. In some embodiments, the mixing with the ammonium solution is conducted at acidic pH conditions. In some embodiments, the mixing with the ammonium solution is conducted at pH of about 3 to about 3.5. In some embodiments, the mixing with the ammonium solution is conducted at a temperature above room temperature. In some embodiments, the mixing with the ammonium solution is conducted at a temperature of at least about 80° C. to about 100° C., including increments therein.

In some embodiments, the ammonium exchanged microspheric material is further ion exchanged with a rare earth ion solution. In some embodiments, the rare earth ion are nitrates of lanthanum, cerium, praseodymium, neodymium, or a mixture of any two or more such nitrates. In some embodiments, the microspheres are contacted with solutions of lanthanum nitrate. In one or more embodiments, the ion exchange step or steps are carried out so that the resulting catalyst contains less than about 0.3%, by weight Na₂O. After ion exchange, the microspheres are dried. Rare earth levels in the range of 0.1% to 12% by weight, specifically 1-5% by weight, and more specifically 2-3% by weight are contemplated. In certain embodiments, the amount of rare earth added to the catalyst as a rare earth oxide will range from about 1 to 5%, typically 2-3 wt % rare earth oxide (REO).

In some embodiments, the FCC catalyst is further calcined. In some embodiments, the calcining is conducted for at least about two hours. Such calcining may be conducted at a temperature of from about 500° C. to about 750° C. In some embodiments, the calcining is conducted in the presence of about 25% v/v steam.

The method may further include steam-treating the FCC catalyst. In some embodiments, the steam-treating conducted at a temperature of at least about 700° C. In some embodiments, the steam-treating is conducted for at least about four hours. In some embodiments, the steam-treating is conducted for about one to about 24 hours.

In another aspect, disclosed herein are microspherical FCC catalysts as prepared by any of the methods disclosed herein.

The zeolite may be incorporated into an amorphous binder that includes gamma-alumina. In some embodiments, a slurry containing zeolite, gamma-alumina, and one or more binders is made and spray-dried to yield microspheres whose average particle size is from about 60 to about 100 micrometers. In some embodiments, the slurry further contains clay.

Alternatively, the Y-zeolite may be produced into high zeolite content microspheres by the in-situ procedure described in U.S. Pat. No. 4,493,902 (“the '902 patent”). The '902 patent discloses FCC catalysts including attrition-resistant, high zeolitic content, catalytically active microspheres containing more than about 40%, preferably 50-70% by weight Y faujasite and methods for making such catalysts by crystallizing more than about 40% sodium Y-zeolite in porous microspheres composed of a mixture of metakaolin (kaolin calcined to undergo a strong endothermic reaction associated with dehydroxylation) and kaolin calcined under conditions more severe than those used to convert kaolin to metakaolin, i.e., kaolin calcined to undergo the characteristic kaolin exothermic reaction, sometimes referred to as the spinel form of calcined kaolin. The microspheres containing the two forms of calcined kaolin could also be immersed in an alkaline sodium silicate solution, which is heated, preferably until the maximum obtainable amount of Y faujasite is crystallized in the microspheres. The microspheres are separated from the sodium silicate mother liquor, ion-exchanged with rare earth, ammonium ions or both to form rare earth or various known stabilized forms of catalysts.

The Y-zeolite may also be produced as zeolite microspheres, which are disclosed in U.S. Pat. No. 6,656,347 (“the '347 patent”) and U.S. Pat. No. 6,942,784 (“the '784 patent”). These zeolite microspheres are macroporous, have sufficient levels of zeolite to be very active and are of a unique morphology to achieve effective conversion of hydrocarbons to cracked gasoline products with improved bottoms cracking under short contact time FCC processing. These zeolite microspheres are produced by a modification of technology described in the '902 patent.

Methods of Use

Without being bound by theory, it is believed that FCC catalysts containing gamma-alumina may demonstrate improvements in bottoms selectivity. “Bottoms” refers to the heaviest fraction of cracked gasoil, also known as heavy cycle oil (HCO), and has very little value. LCO (light cycle oil) is much more valuable since, with further refining, LCO is transformed into diesel fuel. Catalysts that maximize LCO/bottoms ratio as a function of conversion (conversion in FCC is typically defined as 100-LCO-bottoms) are therefore desired.

In another aspect, methods to produce gasoline in an FCC system are provided, where the methods include using an FCC catalyst as described herein.

In another aspect, methods to improve gasoline yield in an FCC system are provided, where the methods include using an FCC catalyst as described herein.

In another aspect, methods to improve gasoline selectivity in an FCC system are provided, wherein the methods include using an FCC catalyst as described herein.

Without being bound by theory, it is believed that use of the FCC catalysts according to the present technology can yield improved selectivities in the FCC process, such as lower coke yield, more olefinic liquids and LPG, and higher ratio of LCO/bottoms.

Thus, in one aspect, provided is a method of cracking a hydrocarbon feed by contacting said feed with a FCC catalyst that includes a microspherical fluid catalytic cracking (FCC) catalyst comprising Y zeolite and gamma-alumina.

In some embodiments, the microspherical FCC catalyst may further include χ-alumina, δ-alumina, θ-alumina, κ-alumina, boehmite or mixtures of two or more thereof. In particular embodiments, the microspherical FCC catalyst may include a mixture gamma-alumina and one or more of χ-alumina, δ-alumina, θ-alumina, κ-alumina, or boehmite. In some embodiments, the microspherical FCC catalyst may include a mixture of gamma-alumina, χ-alumina, and one or more of δ-alumina, θ-alumina, κ-alumina, or boehmite.

In one embodiments, the present method results in a gasoline yield of greater than 1% gasoline at constant coke, when compared to contacting the feed with a FCC catalyst that does not comprise gamma-alumina.

In one embodiment, the method results in 1% lower bottoms at constant coke, when compared to contacting the feed with a FCC catalyst that does not comprise gamma-alumina.

In one embodiment, the method results in 10% lower coke at constant bottoms cracking, when compared to contacting the feed with a FCC catalyst that does not comprise gamma-alumina.

The present invention, thus generally described, will be understood more readily by reference to the following examples, which are provided by way of illustration and are not intended to be limiting of the present invention.

EXAMPLES

Example 1: Preparation of gamma-alumina containing microspheres. A microsphere is prepared using the following exemplary conditions. The slurry for spray dried microspheres is formed by mixing two component slurry in a Cowles mixer. For example, a slurry containing 40% metakaolin, 0-60% clay calcined beyond 1050° C. and up to 60% gamma-Al₂O₃ was spray dried to obtain microspheres. The microsphere is calcined at 1500° F. for 2 hours before crystallization. The microsphere is crystalized for 8-16 hours to form a zeolite Y by the conventional procedures.

Lanthanum-doped γ-Al₂O₃-A containing microspheres were prepared according to the procedure described above. The proportions used in the microspheres are shown in Table 1 below.

TABLE 1 Microsphere formulation of Al₂O₃ containing microspheres Control 20% Al₂O₃-A 30% Al₂O₃-A hydrous (Kaolin), % 40%  0%  0% Meta-Kaolin 40% 40% Calcined clay 60% 40% 30% Al₂O₃-A 20% 30%

The samples were then subjected to the in situ procedure to prepare the FCC catalysts according to conventional procedures. Samples were analyzed and properties of the prepared catalysts are summarized in Table 2 below. NaY indicates samples at the sodium Y-zeolite intermediate, “final product” indicates samples after sodium exchange and calcination. HgPV provides the mercury pore volume in cc/g, TSA provides the total surface area in m²/g, MSA provides the matrix surface area in m²/g, ZSA provides the zeolite surface area in m²/g, and SUCS provides the steamed unit cell size in angstroms (Å). The BET method provides a measurement of the specific surface area in m²/g. REO provides the percentage of rare earth oxide. As seen in Table 2, the total porosity of La-doped γ-Al₂O₃ containing samples at NaY form is very similar to control.

TABLE 2 Properties of La-doped γ-Al₂O₃ containing samples Control 20% Al₂O₃-A 30% Al₂O₃-A NaY HgPV (40-20K) ml/g 0.269 0.299 0.292 Total surface area 525 509 491 matrix surface area 83 77 81 zeolite surface area 442 432 410 Final product % Na₂O 0.19 0.14 0.18 % REO 3.18 3.54 3.61 HgPV (40-20K) ml/g 0.318 0.334 0.339 steamed Total surface area 275 272 263 matrix surface area 73 79 82 zeolite surface area 201 194 181 HgPV (40-20K) ml/g 0.366 0.395 0.385 SUCS 24.346 24.349 24.346

The samples were tested in an Advanced Catalytic Evaluation (ACE) micro-scale reactor. The rare earth content of final products of La-doped γ-Al₂O₃ containing samples is slightly higher than control, as would be expected, because the matrix contains La₂O₃ in addition to La-exchanged zeolite. Without being bound by theory, it is believed that the rare earth level on zeolite should be very similar to control, as seen by the very similar unit cell size (UCS) of all of the steamed samples. As seen in FIG. 1 , in ACE testing of these samples, bottoms conversion increases with increasing alumina addition, with the 30° gamma-alumina containing sample exhibiting 15% lower bottoms at 3% coke. The same sample also yielded 20.5% lower coke at 92.5% bottoms conversion.

Without being bound by theory, it is believed that the gamma-alumina provides a more favorable matrix activity and pore structure that improves bottoms upgrading without increasing coke yield compared to conventional clay-based matrixes.

Sample containing 30% La-doped gamma-alumina containing microsphere was scaled up in a pilot plant and tested in a circulating riser unit (CRU).

Properties of the scaled-up samples are shown in Table 3 below.

TABLE 3 Properties of scaled-up samples Control 30% Al₂O₃-A NaY HGPV (40-20K dia) ml/g 0.34 0.25 total surface area 496 465 matrix surface area 84 74 zeolite surface area 412 391 Final product REO 3.22 3.44 HGPV (40-20K dia) ml/g 0.38 0.3 total surface area 371 388 matrix surface area 274 274 zeolite surface area 97 114 Steamed total surface area 231 202 matrix surface area 68 75 zeolite surface area 163 127 SUCS 24.330 24.307

In CRU testing, FCC catalysts that included 30% La-doped gamma-alumina showed 8.6% lower coke at constant bottoms and 0.9% higher gasoline yield at constant coke.

The FCC catalysts containing 30% La-doped gamma-alumina showed lower coke at constant bottoms and higher gasoline yield at constant coke compared with pilot plant control.

In addition to the catalysts prepared in the above examples, samples containing different type of gamma-alumina (Al₂O₃-B) were also prepared and tested in a CRU. As seen in FIGS. 2A-2B, Al₂O₃-B also exhibited gasoline and coke benefit. As seen in FIGS. 2A-2B, FCC catalysts containing La doped gamma-Al₂O₃ showed 12% lower coke at 75% conversion. Without being bound by theory, it is believed that the increased matrix acidity of the La doped gamma-Al₂O₃ improved bottoms upgrading. Al₂O₃ containing sample also exhibited increased mesoporosity, which is believed to result in improved gasoline yield.

Sample containing 50% La-doped alumina (Al₂O₃-C, mixture of γ-Al₂O₃ and χ-Al₂O₃) and 13% crystalline boehmite (Al₂O₃-D) microsphere was scaled up in a pilot plant and tested in a circulating riser unit (CRU). A different clay based control was also tested in CRU.

Properties of the scaled-up samples are shown in Table 4 below.

TABLE 4 Properties of scaled-up samples Control 50% Al₂O₃-C Final Product REO 2.11 2.22 TSA 342 299 MSA 121 96 ZSA 221 203 Z/M 1.82 2.11 Steamed STSA 217 180 SMSA 102 69 SZSA 114 111 SZSA/SMSA 1.12 1.61

As seen in FIGS. 3A and 3B, in CRU testing, FCC catalysts that included 50% La-doped γ-Al₂O₃, and χ-Al₂O₃ mixture and 13% crystalline boehmite showed lower coke at constant bottoms and higher gasoline yield at constant coke compared with a clay based control.

-   -   Para. A. A catalyst comprising Y zeolite and a gamma-alumina,         wherein the catalyst is a microspherical fluid catalytic         cracking (FCC) catalyst.     -   Para. B. The catalyst of Para. A, comprising about 1 wt % to         about 80 wt % of the gamma-alumina.     -   Para. C. The catalyst of Paras. A or B, comprising about 10 wt %         to about 40 wt % of the gamma-alumina.     -   Para. D. The catalyst of Paras. A-C, wherein the catalyst         further comprises χ-alumina, δ-alumina, θ-alumina, κ-alumina,         boehmite, or mixtures of two or more thereof.     -   Para E. The catalyst of any one of Paras A-D, wherein the         gamma-alumina further comprises a rare earth element.     -   Para. F. The catalyst of Para. E, wherein the rare earth element         comprises ytterbium, gadolinium, cerium, lanthanum, or a mixture         of any two or more thereof.     -   Para. G. The catalyst of Para. F, wherein the rare earth element         comprises lanthanum.     -   Para. H. The catalyst of any one of Paras. A-G, wherein the         gamma-alumina further comprises an alkaline earth element.     -   Para. I. The catalyst of Para. H, wherein the alkaline earth         element comprises barium, calcium, magnesium, or a mixture of         any two or more thereof.     -   Para. J. The catalyst of Para. I, wherein the alkaline earth         metal comprises barium.     -   Para. K. The catalyst of any one of Paras. E-J, wherein the         alumina comprises the rare earth element or the alkaline earth         element in an amount of about 0.1 wt % to about 12 wt %.     -   Para. L. The catalyst of any one of Paras. E-K, wherein the         alumina comprises the rare earth element or the alkaline earth         element in an amount of about 1 wt % to about 10 wt %.     -   Para. M. The catalyst of any one of Paras. A-L, wherein the         catalyst has a phase composition comprising at least about 10 wt         % Y-zeolite.     -   Para. N. The catalyst of any one of Paras A-L, wherein the         catalyst has a phase composition comprising at least about 30 wt         % Y-zeolite.     -   Para. O. The catalyst of any one of Paras. A-L, wherein the         catalyst has a phase composition comprising at least about 60 wt         % Y-zeolite.     -   Para. P. The catalyst of any one of Paras. A-O, wherein the         phase composition further comprises at least about 30 wt %         amorphous material.     -   Para. Q. The catalyst of any one of Paras. A-P, wherein the         Y-zeolite is crystallized as a layer on the surface of a matrix,         wherein the matrix comprises gamma-alumina.     -   Para. R. The catalyst of Para. Q, wherein the matrix comprises         kaolin that has been subjected to calcination through an         exotherm.     -   Para. S The catalyst of Para. R, wherein the matrix comprises         about 20 wt % to about 60 wt % kaolin that has been subjected to         calcination through an exotherm.     -   Para. T. The catalyst of Paras. R or S, wherein the matrix         comprises about 10 wt % kaolin that has been subjected to         calcination through an exotherm.     -   Para. U. The catalyst of any one of Paras A-T, wherein the         Y-zeolite is ion-exchanged to reduce the sodium content of said         catalyst to less than 0.7% by weight Na₂O.     -   Para. V. The catalyst of any one of Paras. A-T, wherein the         Y-zeolite is ion-exchanged to reduce the sodium content of said         catalyst to less than 0.5% by weight Na₂O.     -   Para. W. The catalyst of any one of Paras. M-V, wherein the         Y-zeolite further comprises a rare earth element in the range of         0.1% to 12% by weight.     -   Para. X. The catalyst of Para. W, wherein the rare earth element         is lanthanum, cerium, praseodymium, neodymium, or a mixture of         any two or more.     -   Para. Y. The catalyst of any one of Paras. M-X, wherein the         Y-zeolite is ion-exchanged to include the rare earth element.     -   Para. Z. A method of making a zeolitic fluid catalytic cracking         catalyst, the method comprising:     -   pre-forming precursor microspheres comprising a non-zeolitic         material and gamma-alumina; and     -   in situ crystallizing a zeolite on the pre-formed microspheres         to provide the zeolitic microsphere material.     -   Para. AA. The method of Para. Z, wherein the in situ         crystallizing comprises:     -   mixing the precursor microspheres with sodium silicate, sodium         hydroxide, and water to obtain an alkaline slurry; and     -   heating the alkaline slurry to a temperature, and for a time,         sufficient to crystallize at least about 15 wt % NaY-zeolite in         the microspheres.     -   Para. AB. The method of Paras. Z or AA, wherein at least 40% by         weight Y-zeolite is crystallized in or on the pre-formed         microspheres.     -   Para AC The method of any one of Paras Z-AB, wherein the         precursor microspheres further comprise χ-alumina, δ-alumina,         θ-alumina, χ-alumina, boehmite, or mixtures of two or more         thereof     -   Para. AD. The method of any one of Paras. Z-AC, further         comprising.     -   separating the zeolitic microspheric material from at least a         major portion of alkaline slurry;     -   exchanging sodium cations in the zeolitic microspheric material         with ammonium ions or ammonium ions, and thereafter rare earth         ions;     -   Para. AE. The method of any one of Paras. Z-AD, further         comprising:     -   calcining the zeolitic microspheric material;     -   further exchanging the zeolitic microspheric material with         ammonium ions such that the Na₂O content is reduced to below         0.2%; and     -   further calcining the zeolitic microspheric material.     -   Para. AF. The method of Para. AE, wherein each calcining is         independently conducted for at least about two hours at a         temperature of from about 500° C. to about 750° C.     -   Para. AG. The method of Paras. AE or AF, wherein the calcining         is conducted in the presence of about 25% v/v steam     -   Para. AH. A microspherical FCC catalyst as prepared by the         method of any one of Paras. Z-AG.     -   Para. AI. A method of cracking a hydrocarbon feed comprising         contacting said feed with a FCC catalyst comprising:     -   microspherical fluid catalytic cracking (FCC) catalyst         comprising Y zeolite and gamma-alumina.     -   Para. AJ. The method of Para. AI, wherein the microspherical FCC         catalyst further comprises χ-alumina, δ-alumina, θ-alumina,         κ-alumina, boehmite, or mixtures of two or more thereof.     -   Para. AK. The method according to Paras. AI or AJ, wherein the         method results in a gasoline yield of greater than 1% gasoline         at constant coke, when compared to contacting the feed with a         FCC catalyst that does not comprise gamma-alumina.     -   Para. AL. The method according to Paras. AI or AJ, wherein the         method results in 10% lower bottoms at constant coke, when         compared to contacting the feed with a FCC catalyst that does         not comprise gamma-alumina.     -   Para. AM. The method according to Paras. AI or AJ, wherein the         method results in 10% lower coke at constant bottoms cracking,         when compared to contacting the feed with a FCC catalyst that         does not comprise gamma-alumina.     -   Para. AN. A microspherical catalyst comprising gamma-alumina.     -   Para. AO. The microspherical catalyst of Para AN, wherein the         catalyst further comprises χ-alumina, δ-alumina, θ-alumina,         κ-alumina, boehmite, or mixtures of two or more thereof     -   Para. AP. The microspherical catalyst of Paras. AN or AO,         comprising about 1 wt % to about 80 wt % of the gamma-alumina.     -   Para. AQ. The microspherical catalyst of any one of Paras.         AN-AP, comprising about 10 wt % to about 40 wt % of the         gamma-alumina.     -   Para. AR. The microspherical catalyst of any one of Paras.         AN-AQ, wherein the gamma-alumina further comprises a rare earth         element.     -   Para. AS. The microspherical catalyst of Para. AR, wherein the         rare earth element comprises ytterbium, gadolinium, cerium,         lanthanum, or a mixture of any two or more thereof.     -   Para. AT. The microspherical catalyst of Para. AS, wherein the         rare earth element comprises lanthanum.     -   Para. AU. The microspherical catalyst of any one of Paras.         AN-AT, wherein the gamma-alumina further comprises an alkaline         earth element.     -   Para AV. The microspherical catalyst of Para. AU, wherein the         alkaline earth element comprises barium, calcium, magnesium, or         a mixture of any two or more thereof.     -   Para. AW. The microspherical catalyst of Para. AV, wherein the         alkaline earth metal comprises barium.     -   Para. AX. The microspherical catalyst of any one of Paras.         AR-AW, wherein the alumina comprises the rare earth element or         the alkaline earth element in an amount of about 0.1 wt % to         about 12 wt %.     -   Para. AY. The microspherical catalyst of any one of Paras.         AR-AX, wherein the alumina comprises the rare earth element or         the alkaline earth element in an amount of about 1 wt % to about         10 wt %.     -   Para. AZ. The microspherical catalyst of any one of Paras.         AN-AY, further comprising kaolin that has been subjected to         calcination through an exotherm.     -   Para. BA. The microspherical catalyst of Para. AZ., wherein the         matrix comprises about 20 wt % to about 60 wt % kaolin that has         been subjected to calcination through an exotherm.     -   Para. BB. The microspherical catalyst of Paras. AZ or BA,         wherein the matrix comprises about 40 wt % kaolin that has been         subjected to calcination through an exotherm.     -   Para. BC. The microspherical catalyst of any one of Paras.         AN-BB, further comprising at least about 60 wt % Y-zeolite.     -   Para. BD. The microspherical catalyst of Para. BC, wherein the         Y-zeolite is crystallized as a layer on the surface of the         microspherical catalyst.

The present invention, thus generally described, will be understood more readily by reference to the following examples, which are provided by way of illustration and are not intended to be limiting of the present invention.

While certain embodiments have been illustrated and described, it should be understood that changes and modifications can be made therein in accordance with ordinary skill in the art without departing from the technology in its broader aspects as defined in the following claims.

The embodiments, illustratively described herein may suitably be practiced in the absence of any element or elements, limitation or limitations, not specifically disclosed herein. Thus, for example, the terms “comprising.” “including,” “containing,” etc. shall be read expansively and without limitation. Additionally, the terms and expressions employed herein have been used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the claimed technology. Additionally, the phrase “consisting essentially of” will be understood to include those elements specifically recited and those additional elements that do not materially affect the basic and novel characteristics of the claimed technology. The phrase “consisting of” excludes any element not specified.

The present disclosure is not to be limited in terms of the particular embodiments described in this application. Many modifications and variations can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and compositions within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods, reagents, compounds compositions or biological systems, which can of course vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as “up to,” “at least.” “greater than,” “less than,” and the like, include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member.

All publications, patent applications, issued patents, and other documents referred to in this specification are herein incorporated by reference as if each individual publication, patent application, issued patent, or other document was specifically and individually indicated to be incorporated by reference in its entirety. Definitions that are contained in text incorporated by reference are excluded to the extent that they contradict definitions in this disclosure.

The present technology may include, but is not limited to, the features and combinations of features recited in the following lettered paragraphs, it being understood that the following paragraphs should not be interpreted as limiting the scope of the claims as appended hereto or mandating that all such features must necessarily be included in such claims:

Other embodiments are set forth in the following claims. 

1.-56. (canceled)
 57. A catalyst comprising: a lanthanum-exchanged Y zeolite; and a gamma-alumina matrix, wherein the gamma-alumina matrix is derived from precursor microspheres comprising gamma-alumina and mixed with sodium silicate, wherein the gamma-alumina matrix comprises about 1 wt % to about 5 wt % lanthanum and wherein the catalyst is a microspherical fluid catalytic cracking (FCC) catalyst.
 58. The catalyst of claim 57, comprising about 1 wt % to about 80 wt % of the gamma-alumina.
 59. The catalyst of claim 57, wherein the catalyst further comprises χ-alumina, δ-alumina, θ-alumina, κ-alumina, boehmite, or mixtures of two or more thereof.
 60. The catalyst of claim 57, wherein the gamma-alumina matrix further comprises an alkaline earth element.
 61. The catalyst of claim 60, wherein the alkaline earth element comprises barium, calcium, magnesium, or a mixture of any two or more thereof.
 62. The catalyst of claim 57, wherein the gamma-alumina matrix comprises an alkaline earth element in an amount of about 0.1 wt % to about 12 wt %.
 63. The catalyst of claim 57, wherein the catalyst has a phase composition comprising at least about 10 wt % Y-zeolite.
 64. The catalyst of claim 63, wherein the phase composition further comprises at least about 30 wt % amorphous material.
 65. The catalyst of claim 57, wherein the Y-zeolite is crystallized as a layer on the surface of a matrix, wherein the matrix comprises gamma-alumina.
 66. The catalyst of claim 65, wherein the matrix comprises kaolin that has been subjected to calcination through an exotherm.
 67. The catalyst of claim 66, wherein the matrix comprises about 20 wt % to about 60 wt % kaolin that has been subjected to calcination through an exotherm.
 68. A method of cracking a hydrocarbon feed comprising contacting the feed with a FCC catalyst comprising: microspherical fluid catalytic cracking (FCC) catalyst comprising Y-zeolite and gamma-alumina.
 69. The method of claim 68, wherein the microspherical FCC catalyst further comprises χ-alumina, δ-alumina, θ-alumina, κ-alumina, boehmite, or mixtures of two or more thereof.
 70. The method of claim 68, wherein the method results in a gasoline yield of greater than 1% gasoline at constant coke, when compared to contacting the feed with a FCC catalyst that does not comprise gamma-alumina.
 71. The method of claim 68, wherein the method results in 1% lower bottoms at constant coke, when compared to contacting the feed with a FCC catalyst that does not comprise gamma-alumina.
 72. The method of claim 68, wherein the method results in 10% lower coke at constant bottoms cracking, when compared to contacting the feed with a FCC catalyst that does not comprise gamma-alumina.
 73. A method of making a zeolitic fluid catalytic cracking catalyst, the method comprising: pre-forming precursor microspheres comprising a non-zeolitic material and gamma-alumina; and in situ crystallizing a zeolite on the pre-formed microspheres to provide the zeolitic microsphere material.
 74. The method of claim 73, wherein the in situ crystallizing comprises: mixing the precursor microspheres with sodium silicate, sodium hydroxide, and water to obtain an alkaline slurry; and heating the alkaline slurry to a temperature, and for a time, sufficient to crystallize at least about 15 wt % Na Y-zeolite in the microspheres.
 75. The method of claim 73, wherein at least 40% by weight Y-zeolite is crystallized in or on the pre-formed microspheres.
 76. A microspherical FCC catalyst as prepared by the method of claim
 73. 